Testing & Vision Systems

Semi-Automated Leak Testing Machine Design

The client brings over 40 years of expertise specializing in the design and manufacturing of Fully Integrated Totally Automated Systems, Stand-Alone Assembly Machines, Specialized Machines, and Automated & Secondary Equipment.

Scope

The client approached us to design a semi-automated leak testing machine for testing the cylinder head of an engine. The goal was to detect micro-leaks accurately and increase throughput without compromising on test reliability.

The leak testing principle to be carried out was the Air Sniffing technique. This machine will be an addition to their existing line.

Challenge

Key challenges in designing a semi-automated leak testing machine included:

The machine needed to test both cylinder head caps and cylinder head bodies, two components with different shapes and testing requirements. Designing a single setup to handle both efficiently was a key challenge.
The customer needed a compact machine design to fit into a limited space in the existing line. while still accommodating both parts.
Although the test process would be automated, loading and unloading were manual. So, the design had to ensure easy and safe access for operators, without affecting the cycle time or ergonomics.
Each part had multiple ports and openings that needed to be properly sealed before starting the leak test. This means the fixturing needed to be precise and flexible to ensure accurate results in every test cycle.

Solution

Leveraging our expertise in mechanical design and controls engineering, we delivered a custom-designed semi-automated leak testing machine that met all client requirements.

We categorized our solution into five key steps:

1. Mechanical Design of Leak Testing Machine

After discussing with the client, Sedin’s engineers developed a design concept where both the cylinder head cap and cylinder head body leak tests would run parallelly side-by-side once the cycle starts. This allowed for increased throughput without compromising accuracy.

We optimized the compact design to fit the limited space while maintaining structural integrity and easy access for operators.

2. Precision Fixture Design

To make manual loading and unloading smooth and consistent, the fixtures were designed with foolproof setups, including poka-yoke mechanisms. The fixtures also incorporated resting and clamping units that held the parts securely in place, preventing any errors during testing.

Additionally, PU sealings were integrated and indexed by dedicated cylinders to effectively seal the multiple ports on both cylinder head caps and bodies.

3. Air-Sniffing Leak Testing Technology

The leak test process utilized the air sniffing technique, which required a machine exposed to the open environment for optimal performance. Our precise fixture design ensured that there was zero air leakage during testing, making the system highly accurate and reliable.

We also integrated Cosmo Instruments’ leak tester technology, which enabled precise detection of even the smallest leaks, providing real-time, high-accuracy results.

4. Integrated Part Marking System

To simplify the identification of passed parts, an automatic dot punch marker was added to the machine. This system marked OK parts, making it easy for operators to differentiate between passed and failed components. This feature enhanced the workflow efficiency.

5. Safety and Ergonomics

The machine was designed to meet safety and ergonomic standards recommended by ISO, making it easy and safe for operators to use. Key features included:

– Manual loading/unloading stations positioned for operator comfort and efficiency – Safety interlocks and light curtains to protect personnel – A user-friendly HMI interface showing real-time status, maintenance alerts, and fault diagnostics.

All solutions were developed with full consideration of DFMEA (Design Failure Modes and Effects Analysis) to minimize risk and ensure long-term reliability.

The final design resulted in a compact, high-performing, and user-friendly leak testing machine that met every client requirement with precision. Thanks to our efficient and cost-effective automation solution, the machine runs smoothly with minimal downtime, helping the client boost productivity and maintain consistent output on the line.

Leak testing machine cad modeling

Value and Benefits

The leak testing machine's compact design allowed for simultaneous testing of cylinder head caps and bodies, saving space. This helped the client boost productivity without compromising on quality.

With air-sniffing technology, PU-sealing, and foolproof fixturing, the machine ensured reliable test results with minimal rework.

The machine was designed for operator comfort, with easy handling and safety features to reduce risk and fatigue.

Built to be reliable and cost-effective, the machine required minimal maintenance and integrated smoothly into the existing line. It met all relevant safety and operational standards, ensuring long-term performance.